Tubing Hanger Space-Out Mechanism

ABSTRACT

A space-out mechanism that may be used in a tubing hanger system to install a tubing hanger and rigidize the tubing hanger and a casing hanger within a wellhead housing in a single trip is provided. The space-out mechanism may include two pieces that are configured to rotate against each other such that the axial length of the space-out mechanism can be adjusted to remove any axial gaps created in the installation of the tubing hanger or rigidizing of the tubing hanger and casing hanger within the wellhead housing. The two pieces of the space-out mechanism may include a ramp ring and a piston. The ramp ring and piston may each have ramp surfaces that rotate and bear against each other until the system is rigidized.

TECHNICAL FIELD

The present disclosure relates generally to wellhead systems and, moreparticularly, to tubing hanger space-out mechanisms used to secure atubing hanger in a wellhead in one trip.

BACKGROUND

Conventional wellhead systems include a wellhead housing and asubsurface casing string extending from the wellhead into the well bore.During a drilling procedure, a drilling riser and BOP are installedabove a wellhead housing (casing head) to provide pressure control ascasing is installed, with each casing string having a casing hanger onits upper end for landing on a shoulder within the wellhead housing.Successive casing hangers carrying casing strings of decreasing diameterare installed through the wellbore, and then, a tubing string isinstalled through the well bore. A tubing hanger connectable to theupper end of the tubing string is supported within the wellhead housingabove the last casing hanger, which carries the smallest diameter casingstring, for suspending the tubing string within the casing string. Uponcompletion of this process, the BOP is replaced by a Christmas treeinstalled above the wellhead housing, with the tree having a valve toenable the oil or gas to be produced and directed into flow lines fortransportation to a desired facility.

For various reasons, a tubing hanger or casing hanger within thewellhead may move axially upward, particularly when the wellhead is partof a production system where downhole fluids at elevated temperaturesthermally expand the casing string and thus exert a substantial upwardforce on the casing hanger. Since the casing hanger seal is intended forsealing at a particular location on the wellhead, upward movement of thecasing hanger and the seal assembly is detrimental to reliably sealingthe casing annulus. Further, for various reasons, the casing hanger maystack higher than intended. Thus, it must be ensured that the tubinghanger is properly sized to lock to the wellhead and that the casinghanger is prevented from moving axially in response to such axialforces.

Various tubing hanger designs and methods have been conceived of forensuring the tubing hanger is locked to the wellhead housing and thetubing hanger system and casing hanger are rigidized (locked axially)within the wellhead housing. A tubing hanger, once run in and lockedinto the wellhead, is intended to prevent axial movement of theuppermost casing hanger and seal assembly with respect to the wellhead.Typically, a tubing hanger is run into the wellhead, landed on thecasing hanger, and locked to a locking profile on an inner wall of thewellhead housing, which also acts to secure the casing hanger within thewellhead. To install existing tubing hangers, it is first necessary torun a lead impression tool into the wellhead to measure the distancebetween the top of the casing hanger and the housing locking profile.The lead impression tool is a small block of soft metal, usually lead,which is lowered into the wellhead to take an impression to determinethe internal profile of the wellhead, which after being retrieved can bemeasured to determine the distance between the top of the casing hangerand the housing locking profile. With this information, the tubinghanger can be adjusted at the surface so that once the tubing hanger isrun in and secured to the wellhead, it provides a zero-gap connectionbetween the tubing hanger, the casing hanger, and the wellhead housingand creates any desired pre-load.

This process of taking measurements in the wellhead via a leadimpression tool, retrieving the tool to the surface, and then adjustingand installing a tubing hanger into the wellhead is a time-consuminginstallation process requiring multiple trips into the wellhead. It isnow recognized that a need exists for a tubing hanger system that allowsfor a single-trip installation process.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the present disclosure and itsfeatures and advantages, reference is now made to the followingdescription, taken in conjunction with the accompanying drawings, inwhich:

FIG. 1A is a partial cutaway view of a wellhead system having a tubinghanger system, in accordance with an embodiment of the presentdisclosure;

FIG. 1B is a close-up of the partial cutaway view of the wellhead systemhaving the tubing hanger system of FIG. 1A, in accordance with anembodiment of the present disclosure;

FIG. 1C is a close-up of the partial cutaway view of the wellhead systemhaving the tubing hanger system of FIG. 1A, in accordance with anembodiment of the present disclosure;

FIG. 2 is a partial cutaway view of the tubing hanger system of FIG. 1A,in accordance with an embodiment of the present disclosure;

FIG. 3A is a cutaway view of a ramp ring and a piston of the tubinghanger system of FIG. 1A where the ramp ring is disposed in an initialposition, in accordance with an embodiment of the present disclosure;

FIG. 3B is a cutaway view of a ramp ring and a piston of the tubinghanger system of FIG. 1A where the ramp ring is disposed in a rotatedposition, in accordance with an embodiment of the present disclosure;

FIG. 4 is a partial cross-sectional view of the wellhead system havingthe tubing hanger system of FIG. 1A, in accordance with an embodiment ofthe present disclosure.

FIG. 5A is a top-down cross-sectional view of a tubing hanger system, inaccordance with an embodiment of the present disclosure;

FIG. 5B is a partial perspective view of the tubing hanger system ofFIG. 5A, in accordance with an embodiment of the present disclosure;

FIG. 6A is an isometric view of a tubing hanger system, in accordancewith an embodiment of the present disclosure;

FIG. 6B is a partial top-down cross-sectional view of the tubing hangersystem of FIG. 6A, in accordance with an embodiment of the presentdisclosure;

FIG. 7 is an isometric view of a ramp ring rotating mechanism, inaccordance with an embodiment of the present disclosure;

FIG. 8A is an isometric view of a ramp ring rotating mechanism, inaccordance with an embodiment of the present disclosure;

FIG. 8B is a partial perspective view of the ramp ring rotatingmechanism of FIG. 8A, in accordance with an embodiment of the presentdisclosure;

FIG. 9A is an isometric view of a ramp ring rotating mechanism, inaccordance with an embodiment of the present disclosure;

FIG. 9B is a partial perspective view of the ramp ring rotatingmechanism of FIG. 9A, in accordance with an embodiment of the presentdisclosure;

FIG. 10 is a partial cutaway view of a tubing hanger system, inaccordance with an embodiment of the present disclosure.

FIG. 11 is a partial cross-sectional view of a tubing hanger lockingsystem, in accordance with an embodiment of the present disclosure.

DETAILED DESCRIPTION

Illustrative embodiments of the present disclosure are described indetail herein. In the interest of clarity, not all features of an actualimplementation are described in this specification. It will of course beappreciated that in the development of any such actual embodiment,numerous implementation specific decisions must be made to achievedevelopers' specific goals, such as compliance with system related andbusiness related constraints, which will vary from one implementation toanother. Moreover, it will be appreciated that such a development effortmight be complex and time consuming, but would nevertheless be a routineundertaking for those of ordinary skill in the art having the benefit ofthe present disclosure. Furthermore, in no way should the followingexamples be read to limit, or define, the scope of the disclosure.

Certain embodiments of the present disclosure may be directed to atubing hanger system that may be installed within a wellhead system in asingle trip. The tubing hanger system may include multiple pieces thatare coupled together such that the tubing hanger may be locked to aninner wall of a high-pressure wellhead housing while applying a preloadon a casing hanger, thereby rigidizing the tubing hanger system andcasing hanger within the wellhead housing. The tubing hanger system maybe run into the wellhead system until the tubing hanger system abuts thecasing hanger. Then, the tubing hanger system may be picked up until thetubing hanger system is locked against an inner wall of thehigh-pressure housing. Lastly, a space-out mechanism of the tubinghanger system may actuate such that it takes up any gaps formed axiallyby being picked up, thus rigidizing the tubing hanger system and casinghanger within the wellhead housing. The installation process for thetubing hanger system may be accomplished entirely during a single tripinto the wellhead as opposed to a first trip with a lead impression toolfollowed by an adjustment of the tubing hanger system at the surface anda subsequent trip downhole to install the adjusted tubing hanger system.The disclosed systems and method provide both time savings (since onlyone trip into the wellhead is necessary) and cost savings (since anadditional lead impression tool is not required) compared to existingtubing hanger installation techniques.

Referring now to FIGS. 1A-3B, certain components of a wellhead system 1are illustrated according to one or more embodiments of the presentdisclosure. The illustrated wellhead system 1 may be a subsea wellheadassembly. However, similar techniques may be used in land-based wellheadsystems as well. The wellhead system 1 may include a wellhead housing 2,a casing hanger 10, a tubing hanger system 20, and a locking mechanism60. The casing hanger 10 may be landed within the wellhead housing 2.The tubing hanger system 20 may then be landed upon the casing hanger 10within the wellhead housing 2. Lastly, the locking mechanism 60 may belanded upon the tubing hanger system 20 within the wellhead housing 2.The wellhead housing 2 may include a central bore 3 having lockingprofile 4 disposed thereon. The locking mechanism 60 may engage thelocking profile 4 of the wellhead housing 2 in order to lock the casinghanger 10, the tubing hanger system 20, and the locking mechanism 60 inplace within the wellhead housing 2 and rigidize the system.

The casing hanger 10 may include a casing hanger body 11 having an upperload shoulder 12 and a radially interior profile 13. The upper loadshoulder 12 may be tapered inwards towards the interior profile 13 andridges may be formed along the upper load shoulder 12. However, one ofordinary skill in the art would understand that in other embodiments,the upper load shoulder may be tapered outwards away from the interiorprofile or may not be tapered at all. Additionally, one of ordinaryskill in the art would understand that in other embodiments, the upperload shoulder may be smooth or curved instead of having ridges.

The tubing hanger system 20 may include a tubing hanger body 30 and aspace-out mechanism 100. In one or more embodiments, the space-outmechanism may include a ramp ring 40 and a piston 50. However, one ofordinary skill would understand that space-out mechanisms of otherembodiments may include a plurality of ramp rings or wedges. The tubinghanger body 30, the ramp ring 40, and the piston 50 may be assembledtogether before being inserted into the wellhead housing 2 such that thetubing hanger system 20 may be installed in a single trip. The manner inwhich each of the parts in the tubing hanger system 20 are coupled willbe discussed further below. Additionally, the tubing hanger system 20may be run into the wellhead housing 2 and disposed such that the tubinghanger body 30 seals against the interior profile 13 of the casinghanger body 11 and the piston 50 abuts the upper load shoulder 12 of thecasing hanger 10. In one or more embodiments, to ensure that tubinghanger system 20 is properly seated on the casing hanger 10, one or moresafety lock mechanisms may be used. The safety lock mechanisms accordingto one or more embodiments of the present disclosure will be discussedfurther below.

Still referring to FIGS. 1A-3B, the tubing hanger body 30, according toone or more embodiments of the present disclosure, may include aradially exterior profile 31 defined, in part, by a first sealingprofile 32, a second sealing profile 33, an upward facing contactsurface 34, a downward facing contact surface 35, and an axiallyextending pin slot 36. The first sealing profile 32 may include a firstseal groove 32 a in which a tubing hanger to casing hanger seal 37 isdisposed, a second seal groove 32 b in which an o-ring may be disposed,a third groove 32 c in which a retainer ring 21 may be disposed, and afourth seal groove 32 d in which a first tubing hanger to piston seal 38may be disposed. The second sealing profile 33 may include groove 33 ain which a second tubing hanger to piston seal 39 may be disposed.

Further, the ramp ring 40 of the space-out mechanism 100, according toone or more embodiments of the present disclosure, may include an uppercontact surface 41, ramp surfaces 42, and rotational stop surfaces 43.The ramp ring 40 may be disposed adjacent to the tubing hanger body 30such that the ramp ring 40 is positioned about the second sealingsurface 33 of the tubing hanger body 30 and, at least when the tubinghanger system 20 is run-in and when the tubing hanger system 20 is in afully locked position, the upper contact surface 41 may contact thedownward facing contact surface 35 of the tubing hanger body 30.Additionally, in one or more embodiments, a bottom of the ramp ring 40may have a plurality of ramp surfaces 42 and a plurality of rotationalstop surfaces 43. By way of example, in one or more embodiments, theramp ring 40 may include three ramp surfaces each extending 120°circumferentially about the ramp ring 40. However, one of ordinary skillin the art will understand that in other embodiments, the ramp ring mayhave a single ramp surface and a single rotational stop surface or anycombination of equal numbers of ramp surfaces and rotational stopsurfaces that match the number of ramp surfaces and rotational stopsurfaces of the piston. Further, in one or more embodiments of thepresent disclosure, the ramp surfaces 42 may have a constant 3.5° taper.However, one of ordinary skill in the art will understand that in otherembodiments the ramp surface may include steps or ridges and/or may havea constant or changing taper in the range of 0.5°-7°. Alternatively, theramp surface may include any range of angles, surface geometries, and/orcoatings that prevent rotation once installed.

Additionally, the piston 50 of the space-out mechanism 100 may include alower load shoulder 51, a first interior seal surface 52, a secondinterior seal surface 53, an interior shoulder 54, ramp surfaces 55,rotational stop surfaces 56, and a threaded pin borehole 57. The piston50 may be disposed adjacent to the casing hanger 10, the tubing hangerbody 30, and the ramp ring 40 such that piston is positioned about thefirst sealing surface 32 and the second sealing surface 33 of the tubinghanger body 30. Further, the piston 50 may abut the casing hanger 20 onone side and the ramp ring 40 on the other side. Thus, in one or moreembodiments, the lower load shoulder 51 may abut the upper load shoulder12 of the casing hanger 10. As such, the lower load shoulder 51 may betapered to match the taper of the upper load shoulder 12 of the casinghanger 10 and ridges may be formed along the lower load shoulder 51 tomatch the ridges of the upper load shoulder 12 of the casing hanger 10.However, as discussed above with regard to the upper load shoulder 12 ofthe casing hanger 10, one of ordinary skill in the art would understandthat in other embodiments, the lower load shoulder may be tapered in anumber of ways as long as the taper of the lower load shoulder matchesthe taper of the upper load shoulder. Additionally, one of ordinaryskill in the art would understand that in other embodiments, the upperload shoulder may be smooth or curved instead of having ridges.

Further, the first interior seal surface 52 and second interior sealsurface 53 of the piston 50 may be disposed such that when the tubinghanger system 20 is fully assembled, the first tubing hanger to pistonseal 38 and the second tubing hanger to piston seal 39 may seal againstthe first interior seal surface 52 and the second interior seal surface53 of the piston 50, respectively. Furthermore, when the tubing hangersystem 20 is disposed within the wellhead housing 2 and landed on thecasing hanger 10, the first sealing profile 32 of the tubing hanger body30 may sit within the casing hanger 10 such that the tubing hanger tocasing hanger seal 37 seals against the interior profile 13 of thecasing hanger 10. This sealing profile created between the casing hanger10, the tubing hanger body 30, and the piston 50 may create a pistonforce that acts in a downward direction against the interior shoulder 54of the piston 50, which may hold the piston 50 in abutment with thecasing hanger 10 in the event that the tubing hanger body 30 is shiftedin an upward direction. Additionally, in one or more embodiments, thethreaded pin borehole 57 of the piston 50 may be aligned with the pinslot 36 of the tubing hanger body 30, and an anti-rotation pin 24 may becoupled to the threaded pin borehole 57 such that the anti-rotation pin24 rests within the pin slot 36. This anti-rotation pin, according toone or more embodiments of the present disclosure, may rotationallycouple the piston to the tubing hanger body 30 such that the ramp ring40 may rotate relative to the piston 50 while allowing the tubing hangerbody 30 to move axially relative to the piston 50 so that any gap thatis formed in locking the tubing hanger system 20 and casing hanger 10 tothe wellhead housing 2 may be filled. However, one of ordinary skill inthe art would understand that in other embodiments a variety of methodsmay be used to rotationally secure the piston and the tubing hanger bodysuch that the ramp ring may rotate relative to the tubing hanger bodywithout also rotating the piston.

Furthermore, still referring to FIGS. 1A-3B, the ramp surfaces 55 of thepiston 50 may be configured to abut the ramp surfaces 42 of the rampring 40 at least when the tubing hanger system 20 is run-in and when thetubing hanger system 20 is in a fully locked position. As discussedabove with regard to the ramp surfaces 42 of the ramp ring 40, the rampsurfaces 55 of the piston 50 may be designed in various ways so long asthe ramp surfaces 55 match the ramp surfaces 42. By way of example, inone or more embodiments, the piston may include three ramp surfaces eachextending 120° circumferentially about the piston 50. However, one ofordinary skill in the art will understand that in other embodiments, thepiston may have a single ramp surface and a single rotational stopsurface or any combination of equal numbers of ramp surfaces androtational stop surfaces that match the number of ramp surfaces androtational stop surfaces of the ramp ring. Further, in one or moreembodiments of the present disclosure, the ramp surfaces 55 may have aconstant 3.5° taper. However, one of ordinary skill in the art willunderstand that in other embodiments the ramp surface may include stepsor ridges and/or may have a constant or changing taper in the range of0.5°-7°. One of ordinary skill will appreciate that the ramp surfacesare designed such that the contact between the ramp surfaces isself-locking and compressive forces between the surfaces will not causethe piston and ramp ring to rotate relative to each other once thetubing hanger system is in the fully locked position. Further, therotational stop surfaces 56 of the piston 50 and the rotational stopsurfaces 43 of the ramp ring 40 may be configured to abut each other atleast when the tubing hanger system 20 is run in and may prevent thepiston and ramp ring from rotating relative to each other in onedirection.

Additionally, the locking mechanism 60, according to one or moreembodiments of the present disclosure, may include a locking mandrel 61and locking dogs 62. The plurality of locking dogs 62 may be supportedaround the locking mandrel 61. The locking mechanism 60 may be run intothe wellhead housing 2 until the locking mechanism 60 abuts the upwardfacing contact surface 34 of the tubing hanger body 30. In one or moreembodiments, a bottom surface of the locking dogs 62 may directly abutthe upward facing contact surface 34 and may be pushed outward into thelocking profile 4 of the wellhead housing 2 by a compressive forcecaused by the locking mandrel 61 pushing down on the locking dogs 62.The locking dogs 62 may have ridges disposed on an outer surface thatmatch the locking profile 4 disposed along the central bore 3 of thewellhead housing 2.

Further, the tubing hanger system 20 may include one or more safetylocks to ensure that the system is properly run into the wellheadhousing 2 and features of the system are not activated prematurely. Byway of example, in one or more embodiments, a retainer ring 21 may beincluded in the tubing hanger system 20 so as to make sure that thepiston 50 is properly seated upon the casing hanger 10 and the seals ofthe tubing hanger body 30 are set within the piston 50 and the casinghanger 10 as necessary for the system to function properly. The retainerring 21 may be a split ring disposed within the third groove 32 c of thetubing hanger body 30 and may have an uncollapsed outer diameter that isgreater than both the diameter of the interior profile 13 of the casinghousing 10 and the first interior seal surface 52 of the piston 50.Further, in a pre-run-in assembled state, the third groove 32 c and theretainer ring 21 may be disposed below the lower load shoulder 51 of thepiston 50. This disposition of the retainer ring 21 and third groove 32c may be such that the lower load shoulder 51 of the piston 50 cannotabut the upper load shoulder 12 of the casing hanger 10 until theretainer ring 21 is collapsed into the third groove 32 c. The retainerring 21 may include an upper contact surface 22 and a lower contactsurface 23. The lower contact surface 23 may be tapered such thatdownward forces from the piston 50 and/or tubing hanger body 30 duringrun-in push the tapered lower contact surface 23 into an interior edgeof the upper load shoulder 12 of the casing hanger 10 and cause theretainer ring 21 to collapse into the third groove 32c. Once collapsed,the outer diameter of the retainer ring 21 may be smaller than theinterior profile 13 of the casing hanger 10, allowing the tubing hangersystem 20 to properly seat within and against the casing hanger 10.Thus, in one or more embodiments, the retainer ring 21 needs to becollapsed in order for the lower load shoulder 51 of the piston 50 to beable to abut the upper load shoulder 12 of the casing hanger 10.Additionally, various other safety locks may be used in one or moreembodiments of the present disclosure.

Referring now to FIG. 4, another safety mechanism according to one ormore embodiments of the present disclosure is illustrated. A springloaded pin disposed within the ramp ring 40 may be installed duringassembly of the tubing hanger system 20 and engage the tubing hangerbody 30 so as to rotationally lock the ramp ring to the tubing hangerbody until the proper time in the tubing hanger system run-in in whichthe ramp ring must be rotationally actuated in order to take up anyaxial space created by the installation procedure.

The safety mechanism of the tubing hanger system 20 may include a safetylock pin 70, a safety lock spring 71, and a safety lock rod 72. Thesafety lock pin 70 and the safety lock spring 71 may be disposed withinthe ramp ring 40, and the safety lock rod 72 may be disposed within thetubing hanger body 30. The ramp ring 40, in one or more embodiments, mayinclude a pin blind hole 44 disposed in an upper contact surface 41 anda pin securing mechanism 45. The safety lock spring 71 may be disposedwithin the pin blind hole 44 abutting a bottom of the blind hole, andthe safety lock 70 pin may be disposed above the safety lock spring 71in the blind hole such that the safety lock pin 70 is pushed up towardsthe tubing hanger body 30. The safety lock pin 70 may include a safetylock pin body 70 a and a safety lock pin flange 70 b, in which thediameter of the safety lock pin flange 70 b is greater than the diameterof the safety lock pin body 70 a. The pin securing mechanism 45 may bedisposed in the opening of the pin blind hole 44 and may have an innerdiameter larger than the safety lock pin body 70 a but smaller than thediameter of the safety lock pin flange 70 b such that the safety lockpin 70 is maintained within the pin blind hole 44 while the safety lockpin body 70 a is able to extend past the upper contact surface 41 of theramp ring 40.

Additionally, the tubing hanger body 30, in one or more embodiments, mayinclude an elongated hole 58 that extends from an upward facing contactsurface 34 to a downward facing contact surface 35. Further, a pincounterbore 59 may be sunk into the downward facing contact surface 35and concentric with the hole 58. An inner diameter of the pincounterbore 59 may be slightly larger than the outer diameter of thesafety lock pin body 70 a, and the pin counterbore 59 may be configuredto receive the safety lock pin 70 when the tubing hanger system 20 isassembled before run-in. Further, the safety lock rod 72 may be disposedwithin the hole 58. The safety lock rod 72 may be longer than the lengthof the hole 58 and the pin counterbore 59 such that when the safety lockpin 70 extends into the pin counterbore 59, the top end 72 a of thesafety lock rod 72 extends above the upward facing contact surface 34and when the safety lock rod 72 is compressed down to the upward facingcontact surface 34 into the hole 58, the bottom end 72 b of the safetylock rod 72 is even with or extends slightly below the downward facingcontact surface 35.

Further referring to FIG. 4, in one or more embodiments of the presentdisclosure, when the tubing hanger system 20 is assembled before run-in,the safety lock pin 70 may engage the pin counterbore 59. During theinstallation of the tubing hanger system 20 within a wellhead housing,installation of a locking mechanism may cause a locking mandrel tocompress the safety lock rod 72 into the hole 58, which will cause thebottom end 72 b of the safety lock rod 72 to push the safety lock pin 70out of the pin counterbore 59. Once the safety lock pin 70 is removedfrom the pin counterbore 59, the tubing hanger body 30 and the ramp ring40 will no longer be rotationally locked with respect to each otherallowing the ramp ring 40 to rotate relative to the piston 50 alongtheir respective ramp surfaces in order to remove any axial gaps in thetubing hanger system 20 created during the process of locking the tubinghanger system within the wellhead housing.

Referring now to FIGS. 5A and 5B, a tubing hanger system 520, accordingto one or more embodiments of the present disclosure, is illustrated. Asdiscussed previously, the tubing hanger system 520 may include a tubinghanger body 530 and a space-out mechanism 500. Further, the space-outmechanism 500 may include a ramp ring 540 and a piston 550.Additionally, in one or more embodiments, the ramp ring 540 of thespace-out mechanism 500 may be rotationally coupled to the tubing hangerbody 530 by a circumferential spring mechanism 580. The circumferentialspring mechanism 580 may be coupled to the ramp ring 540 on a first endand to the tubing hanger body 530 on a second end. The circumferentialspring mechanism 580 may include a spring 581, spring connectors 582, atransfer block 583, and bolts 584. The spring 581 may be disposed withina circumferential groove 531 located on the second sealing profile 533of the tubing hanger body 530. The circumferential groove 531 may bedisposed between the downward facing contact surface (not shown) of thetubing hanger body 530 and the fourth seal groove (not shown), which isdisposed on the second sealing profile 533 of the tubing hanger body530. Further, the spring 581 may be directly coupled to the tubinghanger body 530 by a spring connector 582 on a first end of thecircumferential groove 531 and may be directly coupled to the transferblock 583 by a spring connector 582 within a distal portion of thecircumferential groove 531. The transfer block 583 may be directlycoupled to the ramp ring 540 by bolts 584.

In one or more embodiments, when assembling the tubing hanger system 520before run-in, the circumferential spring mechanism 580 may be preloadedsuch that when a safety mechanism rotationally locking the tubing hangerbody 530 and the ramp ring 540 is disengaged, the space-out mechanism500 self-actuates to rotate the ramp ring 540 against the piston 550 toextend the space-out mechanism 500 axially and remove any axial gapsthat have formed during installation of the tubing hanger system 520into wellhead housing. When the space-out mechanism 500 is actuated, therotation of the ramp ring will cause the ramp surface of the ramp ring540 to bear against and rotate against the ramp surface of the piston530 and extend the space-out mechanism 500 axially.

By way of example, in one or more embodiments, the space-out mechanism500 may be configured such that the preload puts the spring 581 intension and releasing the safety mechanism causes the spring 581 to pullthe ramp ring 540 causing it to rotate against the piston 550. However,one of ordinary skill would appreciate that in other embodiments, thespring 581 may be preloaded in compression such that releasing thesafety mechanism causes the spring to push the ramp ring 540 causing itto rotate against the piston 550. Additionally, while a singe preloadedspring 581 is illustrated in FIGS. 5A and 5B, one of ordinary skillwould appreciate that in other embodiments, there may be multiplesprings situated in series or in parallel and preloaded in tension,compression, or torsion so as to rotate a ramp surface of the ramp ring540 against a ramp surface of the piston 550 causing the space-outmechanism to extend axially and fill in any axial gaps created whilerigidizing the tubing hanger system and casing hanger within thewellhead housing.

Referring now to FIGS. 6A and 6B, a tubing hanger system 620, accordingto one or more embodiments of the present disclosure, is illustrated. Asdiscussed previously, the tubing hanger system 620 may include a tubinghanger body 630 and a space-out mechanism 600. Further, the space-outmechanism 600 may include a ramp ring 640 and a piston 650.Additionally, in one or more embodiments, the space-out mechanism mayinclude a ratchet mechanism 680 disposed inside the tubing hanger system620 that is configured to allow a user to remotely rotate the ramp ring640 as necessary during run-in and the process of rigidizing the tubinghanger system 620 within the wellhead housing. The ramp ring 640 mayinclude a plurality of inclined grooves 641 disposed circumferentiallyalong its inner diameter. The ratchet mechanism 680 may be configured toengage the grooves 641 of the ramp ring 640 such that each stroke of theratchet mechanism rotates the ramp ring 640 by the radial distance of asingle groove. The ratchet mechanism 680, according to one or moreembodiments of the present disclosure, may be a short stroke piston witha ratchet. The ratchet mechanism 680 may include a piston 681, a spring682, an actuation arm 683, and a lever 684. The piston 681 and thespring 682 may be coaxially disposed with one end of the actuation arm683 coupled to one end of the piston 681. Further, the other end of theactuation arm may be coupled to the lever 684, which is itself pinned toa non-moving portion of the piston 681, in order to force the lever 684to rotate about the pinned connection. The piston 681 may be remotelycontrolled by a user so as to actuate the ratchet mechanism 680 bypulling the actuation arm 683 such that the lever 684 rotates out of thegroove it is sitting in and then allowing the lever 684 to rotate backagainst the edge of a groove under the force of the spring 682, whichcauses the actuation arm to return the lever to its resting position,such that the lever 684 now engages an adjacent groove; thus, rotatingthe ramp ring 640, accordingly. Further, as discussed above, rotatingthe ramp ring 640 causes the ramp ring 640 to shift against the piston650 to extend the space-out mechanism 600 axially and remove any axialgaps that have formed during installation of the tubing hanger system620 into the wellhead housing. When the space-out mechanism 600 isactuated, the rotation of the ramp ring will cause the ramp surface ofthe ramp ring 640 to bear against and rotate against the ramp surface ofthe piston 630 and extend the space-out mechanism 600 axially.

Referring now to FIG. 7, a ramp ring rotating mechanism 780, accordingto one or more embodiments of the present disclosure, is illustrated. Aspace-out mechanism may include the ramp ring rotating mechanism 780coupled to a ramp ring. The ramp ring rotating mechanism 780 may includea piston 781 and a curved piston rod 782. In one or more embodiments,the curved piston rod 782 may be 3-D printed. Further, the curved pistonrod 782 may be disposed within the piston 781 and extend from the piston781. An end of the curved piston rod 782 may be coupled to the rampring, and actuating the piston 781 may cause the curved piston rod 782to extend, thus causing the ramp ring to rotate relative to a tubinghanger body and a piston 750 of a tubing hanger system. Further, asdiscussed above, rotating the ramp ring may cause the ramp ring to shiftagainst the piston 750 to extend the space-out mechanism axially andremove any axial gaps that have formed during installation of the tubinghanger system into a wellhead housing. When the space-out mechanism isactuated, the rotation of the ramp ring may cause the ramp surface ofthe ramp ring to bear against and rotate against the ramp surface of thepiston 750 and extend the space-out mechanism axially.

Referring now to FIGS. 8A and 8B, a ramp ring rotating mechanism 880,according to one or more embodiments of the present disclosure, isillustrated. A space-out mechanism 800 may include the ramp ringrotating mechanism 880 coupled to a ramp ring 840. The ramp ringrotating mechanism 880 may include a piston 881, an arm 882, and aslider 883. In one or more embodiments, the arm 882 may be coupled tothe piston 881 and may be rotated by way of actuation of the piston 881,which may be operated remotely by a user. An end of the arm 882 may becoupled to a first end of the slider 883, and a second end of the slider883 may be coupled to the ramp ring 840. In one or more embodiments, theslider 883 may be coupled to the arm 882 and the ramp ring 840 by pins.Further, actuating the piston 881 may cause the arm 882 to rotate, thuscausing the slider 883 to rotate about the pinned connection to the arm882 and rotating the ramp ring 840 relative to a tubing hanger body anda piston 850 of a tubing hanger system. Further, as discussed above,rotating the ramp ring 840 may cause the ramp ring 840 to shift againstthe piston 850 to extend the space-out mechanism 800 axially and removeany axial gaps that have formed during installation of the tubing hangersystem into a wellhead housing. When the space-out mechanism 800 isactuated, the rotation of the ramp ring 840 may cause the ramp surfaceof the ramp ring 840 to bear against and rotate against the ramp surfaceof the piston 850 and extend the space-out mechanism 800 axially.

Referring now to FIGS. 9A and 9B, a ramp ring rotating mechanism 980,according to one or more embodiments of the present disclosure, isillustrated. A space-out mechanism 900 may include the ramp ringrotating mechanism 980 coupled to a ramp ring 940. The ramp ringrotating mechanism 980 may be a geared mechanism and may include acurved rack 981 and a pinion 982. In one or more embodiments, the curvedrack 981 may be coupled to a ramp ring 940 and the pinion 982. Further,rotation of the pinion 982 may cause rotation of the ramp ring 940 byway of the curved rack 981, and the pinion 982 may be rotated by remoteoperation by a user. Therefore, in one or more embodiments, rotation ofthe pinion 982 may cause the ramp ring 940 to rotate relative to atubing hanger body and a piston 950 of a tubing hanger system. Further,as discussed above, rotating the ramp ring 940 may cause the ramp ring940 to shift against the piston 950 to extend the space-out mechanism900 axially and remove any axial gaps that have formed duringinstallation of the tubing hanger system into a wellhead housing. Whenthe space-out mechanism 900 is actuated, the rotation of the ramp ring940 may cause the ramp surface of the ramp ring 940 to bear against androtate against the ramp surface of the piston 950 and extend thespace-out mechanism 900 axially.

Referring now to FIG. 10, a partial cutaway view of a tubing hangersystem 1020, according to one or more embodiments of the presentdisclosure, is illustrated. The tubing hanger system 1020 may include atubing hanger body 1030 and a space-out mechanism 1000. The space-outmechanism 1000 may include a first ramp ring 1040, a second ramp ring1090, and a piston 1050. The piston 1050 may include ramp surfaces 1055and rotational stop surfaces 1056.

Further, the first ramp ring 1040 may include lower ramp surfaces 1042and an upper ramp surface 1046. The lower ramp surfaces 1042 may contactthe ramp surfaces 1055 of the piston 1050, and in one or moreembodiments, the ramp surfaces 1042 of the ramp ring 1040 and the rampsurfaces 1055 of the piston 1050 may match in number and taper. By wayof example, in one or more embodiments, the ramp ring 1040 may includemultiple ramp surfaces 1042 each extending 120° circumferentially aboutthe ramp ring 1040. However, one of ordinary skill in the art willunderstand that in other embodiments, the ramp ring may have a singleramp surface and a single rotational stop surface or any combination ofequal numbers of ramp surfaces and rotational stop surfaces that matchthe number of ramp surfaces and rotational stop surfaces of the piston.Further, in one or more embodiments of the present disclosure, the rampsurfaces 1042, 1055 may all have a constant 4° taper. However, one ofordinary skill in the art will understand that in other embodiments theramp surface may include steps or ridges and/or may have a constant orchanging taper in the range of 0.5°-7°. Additionally, the upper rampsurface 1046 of the first ramp ring 1040 may have a constant taper. Inone or more embodiments, the upper ramp surface 1046 may have a constanttaper of 0.5°. However, one of ordinary skill in the art will understandthat in other embodiments the ramp surface may include steps or ridgesand/or may have a constant or changing taper in the range of 0.5°-7°.Further, a pin blind hole 1047 may be formed on the upper ramp surface1046.

Furthermore, the second ramp ring 1090 may include a lower ramp surface1091 and an upper contact surface 1092. The lower ramp surface 1091 ofthe second ramp ring 1090 may contact and may match the taper of theupper ramp surface 1046 of the first ramp ring 1040. As discussed above,the lower ramp surface 1091 may have a constant taper of 0.5°. However,one of ordinary skill in the art will understand that in otherembodiments the lower ramp surface 1091 may include steps or ridgesand/or may have a constant or changing taper in the range of 0.5°-7°that matches that of the upper ramp surface 1046 of the first ramp ring1040. Further, a pin blind hole 1093 may be formed on the lower rampsurface 1091 and may be coaxially aligned with the pin blind hole 1047of the first ramp ring 1040 during assembly. Further, a shear pin 1095may be disposed within the aligned pin blind holes 1047, 1093 torotationally lock the first ramp ring 1040 and the second ramp ring 1090until a sufficient piston force is applied to either the first ramp ring1040 or the second ramp ring 1090 to shear the shear pin 1095 whenlocking and rigidizing the tubing hanger system 1020 within a wellheadhousing.

Additionally, the tubing hanger body 1030 may include a downward facingcontact surface 1035. The downward facing contact surface 1035 of thetubing hanger body 1030 may contact upper contact surface 1092 of thesecond ramp ring 1090 at least when the tubing hanger system 1020 isrun-in and when the tubing hanger system 1020 is in a fully locked andrigidized position within the wellhead housing.

Referring now to FIG. 11, a tubing hanger locking system 1100, accordingto one or more embodiments of the present disclosure, is illustrated.The tubing hanger locking system 1100 may include, at least, a piston1110, locking dogs 1120, and a wedge 1130. The piston 1110, the lockingdogs 1120, and the wedge 1130 may be configured and coupled such thatthe tubing hanger locking system 1100 locks a tubing hanger in placewithin a wellhead housing and rigidizes a tubing hanger and casinghanger within the wellhead housing.

While one or more embodiments of the present disclosure may include apiston 50, 550, 650, 750, 850, 950, 1050, one of ordinary skill wouldappreciate that in other embodiments, a space-out mechanism of a tubinghanger system may instead include a lower member, which may be anon-actuating member. However, as discussed above with respect topistons of one or more embodiments of the present disclosure, the lowermember may include, at least, ramp surfaces and rotational stop surfacesand may be configured to interact with a ramp ring in order to lock acasing hanger and a tubing hanger system in place within a wellheadhousing and rigidize the system.

It should be understood that the present disclosure contemplates amethod to lock and rigidize a tubing hanger system and casing hangerwithin a wellhead housing. The present disclosure also contemplates amethod to assemble a tubing hanger system.

In one or more embodiments of the present disclosure, assembly of thetubing hanger system may include disposing a space-out mechanism about afirst sealing profile and second sealing profile of a tubing hangerbody. Further, in one or more embodiments where the space-out mechanismincludes a ramp ring and a piston, a ramp ring may be disposed about thesecond sealing profile of the tubing hanger body. Then, in one or moreembodiments including a safety mechanism for locking a rotation of theramp ring relative to the tubing hanger body, the portions of the safetymechanism in the ramp ring and in the tubing hanger body may be alignedand coupled. This may further include disposing a safety lock spring ina pin blind hole, disposing a safety lock pin on top of the safety lockspring in the pin blind hole, and disposing a pin securing mechanisminto the opening of the pin blind hole. Further, once the safetymechanism for locking a rotation of the ramp ring relative to the tubinghanger body is properly aligned and the safety lock pin is inserted intothe pin counterbore of the tubing hanger body, a safety lock rod may bedisposed within an elongated hole in the tubing hanger body. Further, ifa space-out mechanism requires a pre-load to be applied to a mechanismconfigured to rotate the ramp ring relative to the tubing hanger body,the pre-load will be applied before rotationally locking the ramp ringand the tubing hanger body by way of the safety mechanism.

Then, in one or more embodiments, a piston may be disposed about thefirst sealing profile and the second sealing profile of the tubinghanger body. Once the piston is properly installed such that the sealsof the tubing hanger body are properly located within the piston, thepiston and the tubing hanger body may be aligned such that theanti-rotation pin may be threaded into the threaded pin borehole of thepiston and extend into a pin slot of the tubing hanger body.Additionally, in one or more embodiments, a retainer ring may bedisposed within a third groove of the tubing hanger body.

Additionally, in one or more embodiments of the present disclosure,locking and rigidizing a tubing hanger system and casing hanger within awellhead housing may include running an assembled tubing hanger systeminto the wellhead housing, landing the tubing hanger system on thecasing hanger and sealing a tubing hanger to casing hanger seal of thetubing hanger body against the casing hanger. Landing the tubing hangersystem on the casing hanger may further include collapsing a retainingring into a third groove of the tubing hanger body. Then, in one or moreembodiments, a seal test on the tubing hanger to casing hanger seal maybe performed. Once the seal test confirms that the seals are properlyset, the tubing hanger may be locked. The process of locking the tubinghanger may activate the safety lock rod and engage the locking dogs intotheir locking profile within the wellhead housing. Then, the tubinghanger body may be lifted to preload the locking mechanism in placewithin the wellhead housing.

In one or more embodiments, the space-out mechanism may then beactuated, taking up any axial gaps created by lifting on the tubinghanger body and rigidizing the tubing hanger system within the wellheadhousing. Actuating the space-out mechanism may further include unlockinga safety mechanism. Unlocking the safety mechanism may includecompressing a safety locking rod into an elongated hole of the tubinghanger body and pushing a safety lock pin out of a pin counterbore ofthe tubing hanger body such that the ramp ring is no longer rotationallylocked to the tubing hanger body. Actuating the space-out mechanism mayfurther include moving the piston down to push against the casinghanger, rotating the ramp ring, and filling the gap between the pistonand the tubing hanger body. Once the space-out mechanism has beenactivated to rigidize the tubing hanger body and the casing body withinthe wellhead housing, the casing hanger seal may be seal tested toensure that it is still properly sealing. Then, finally, the tubinghanger system may be released.

Although the present disclosure and its advantages have been describedin detail, it should be understood that various changes, substitutionsand alterations can be made herein without departing from the spirit andscope of the disclosure as defined by the following claims.

What is claimed is:
 1. A system, comprising: a tubing hanger body; and aspace-out mechanism, the space-out mechanism comprising: a ramp ringhaving a tapered surface; and a lower member coupled to the tubinghanger body, the lower member having a tapered surface, wherein the rampring is configured to rotate relative to the tubing hanger body and thelower member, and wherein the ramp ring ramp surface and the lowermember ramp surface are configured to bear against each other torigidize the system.
 2. The system of claim 1, wherein the taperedsurfaces of the ramp ring and the lower member are complimentary.
 3. Thesystem of claim 2, wherein the taper of the ramp ring ramp surface andthe taper of the lower member ramp surface have a slope between 0.5° and7°.
 4. The system of claim 1, wherein: the ramp ring further comprises:a ramp ring rotational stop surface; the lower member further comprises:a lower member rotational stop surface; and the ramp ring rotationalstop surface is configured to abut the lower member rotation stopsurface.
 5. The system of claim 1, further comprising: an anti-rotationpin, wherein: the tubing hanger body further comprises: a radiallyexterior profile having a pin slot; the lower member further comprises:a threaded pin borehole; the anti-rotation pin is coupled to thethreaded pin borehole and disposed within the pin slot; and theanti-rotation pin is configured to rotationally lock the lower member tothe tubing hanger body.
 6. The system of claim 1, wherein: the tubinghanger body comprises: a downward facing contact surface; and a radiallyexterior profile having a first sealing profile and a second sealingprofile; the lower member further comprises: a first interior sealsurface; and a second interior seal surface; the ramp ring furthercomprises: an upper contact surface; the upper contact surface of theramp ring is configured to abut the downward facing contact surface ofthe tubing hanger body; a first seal is formed between the firstinterior seal surface of the lower member and the first sealing profileof the tubing hanger body; and a second seal is formed between thesecond interior seal surface of the lower member and the second sealingprofile of the tubing hanger body.
 7. The system of claim 6, wherein thelower member further comprises: an interior shoulder disposed betweenthe first interior seal surface and the second interior seal surface,wherein the interior shoulder, the first seal, and the second seal areconfigured to create a piston force axially downward on the lowermember.
 8. The system of claim 1, further comprising: a casing hanger;and a locking mechanism, wherein the locking mechanism is configured tolock the casing hanger, the tubing hanger body, the space-out mechanism,and the locking mechanism in place within a wellhead housing.
 9. Thesystem of claim 8, wherein: the casing hanger comprises: an upper loadshoulder; and a radially interior profile; the tubing hanger bodycomprises: an upward facing contact surface; a downward facing contactsurface; and a radially exterior profile having a first sealing profileand a second sealing profile; the lower member further comprises: alower load shoulder; a first interior seal surface; and a secondinterior seal surface; the ramp ring further comprises: an upper contactsurface; the lower load shoulder of the lower member is configured toabut the upper load shoulder of the casing hanger; the upper contactsurface of the ramp ring is configured to abut the downward facingcontact surface of the tubing hanger body; the locking mechanism abutsthe upward facing contact surface of the tubing hanger body; a firstseal is formed between the first interior seal surface of the lowermember and the first sealing profile of the tubing hanger body; a secondseal is formed between the second interior seal surface of the lowermember and the second sealing profile of the tubing hanger body; and athird seal is formed between the first sealing profile of the tubinghanger body and the interior profile of the casing hanger.
 10. Thesystem of claim 9, wherein the lower member further comprises: aninterior shoulder disposed between the first interior seal surface andthe second interior seal surface, wherein the interior shoulder, thefirst seal, and the second seal are configured to create a piston forceaxially downward on the lower member within the wellhead housing. 11.The system of claim 1, further comprising: a safety mechanism disposedwithin and between the ramp ring and the tubing hanger body, whereinwhen the safety mechanism is in a locked position, the ramp ring cannotrotate relative to the tubing hanger body, and when the safety mechanismis in an unlocked position, the ramp ring can rotate relative to thetubing hanger body.
 12. The system of claim 1, further comprising: aretainer ring disposed within a groove in a radially exterior profile ofthe tubing hanger body, wherein the retainer ring is configured tocollapse into the groove in the radially exterior profile of the tubinghanger body.
 13. A method, comprising: assembling a tubing hangersystem, the tubing hanger system including a tubing hanger body and aspace-out mechanism; running the tubing hanger system into a wellheadhousing until the tubing hanger system lands on a casing hanger; lockingthe tubing hanger system to the wellhead housing; lifting the tubinghanger system; and actuating the space-out mechanism to rigidize thetubing hanger system within the wellhead housing.
 14. The method ofclaim 13, wherein: the space-out mechanism comprises: a ramp ring havinga tapered surface; and a lower member having a tapered surface, whereinthe ramp ring tapered surface and the lower member tapered surface areconfigured to bear against each other; the tubing hanger body comprises:a radially exterior profile having a first sealing profile and a secondsealing profile; and assembling the tubing hanger system comprises:disposing the ramp ring about the second sealing profile of the tubinghanger body; disposing the lower member about the first sealing profileand the second sealing profile of the tubing hanger body; androtationally locking the lower member to the tubing hanger body.
 15. Themethod of claim 14, wherein: the lower member comprises: a threaded pinborehole; the radially exterior profile of the tubing hanger bodyfurther comprises: a pin slot; rotationally locking the lower member tothe tubing hanger body comprises: aligning the threaded pin borehole ofthe lower member with the pin slot of the tubing hanger body; andthreading an anti-rotation pin into the threaded pin borehole of thelower member, wherein the anti-rotation pin is configured to extend intothe pin slot of the tubing hanger body when threaded into the threadedpin borehole.
 16. The method of claim 14, wherein the tapered surfacesof the ramp ring and the lower member are complementary.
 17. The methodof claim 14, further comprising: installing a safety mechanism into thetubing hanger system, wherein when the safety mechanism is in a lockedposition, the ramp ring cannot rotate relative to the tubing hangerbody, and when the safety mechanism is in an unlocked position, the rampring can rotate relative to the tubing hanger body.
 18. The method ofclaim 13, wherein: the tubing hanger body comprises: a radially exteriorprofile having a first sealing profile and a second sealing profile,wherein the first sealing profile includes a first seal groove, a secondseal groove, and a third seal groove, and wherein the second sealingprofile includes a fourth seal groove; and assembling the tubing hangersystem comprises: installing a tubing hanger to casing hanger seal inthe first seal groove; installing an o-ring in the second seal groove;installing a first tubing hanger to lower member seal in the third sealgroove; and installing a second tubing hanger to lower member seal inthe fourth groove.
 19. The method of claim 18, wherein: the firstsealing profile of the radially exterior profile of the tubing hangerbody further comprises: a fifth groove; assembling the tubing hangersystem further comprises: installing a retainer ring within the fifthgroove; and running the tubing hanger system into a wellhead housinguntil the tubing hanger system lands on a casing hanger comprises:collapsing the retainer ring into the fifth groove.
 20. The method ofclaim 18, further comprising: forming a seal between the casing hangerbody and the tubing hanger body using the tubing hanger to casing hangerseal; and performing a seal test on the seal formed between the casinghanger body and the tubing hanger body using the tubing hanger to casinghanger seal.